Safety and Regulation Division Kateena Street, Regency Park 5010 Phone 1300 882 248 Fax (08) 8348 9533 This Information Manual details the requirements to obtain approval for road use of an Individually Constructed Vehicle (ICV). The construction of passenger vehicles is a complex and usually time consuming project. The Department for Transport, Energy and Infrastructures (DTEI) aim is to ensure that the requirements of Australian Design Rules (ADRs) and regulations related to safety and environmental protection are equivalent to production vehicles. Not only must high quality components be used, but all components used in the design must be correctly matched to each other to ensure safe operation, performance and compliance with the relevant standards. The motor vehicle must be considered as a complete package. All requirements of the Australian Design Rules (ADRs) and South Australian Road Trafc (Vehicle Standards) Rules are not fully detailed. It is the vehicle constructors responsibility to ensure that an ICV complies as fully as possible with the ADRs and the South Australian Road Trafc (Vehicle Standards) Rules 1999. MR850 03/07 Description Page Number Denition of an Individually Constructed Vehicle 3 Engineering Requirements 3 Recommended Construction & Approval Process 3 Applications (Overview of Items to Address) 3 1. Engine and driveline 4 2. Brakes 4 3. Wheels and tyres 4 4. Axles and suspension 4 5. Steering 4 6. Chassis or frame 4 7. Body 4 8. Seats and seatbelts 5 9. Emissions and noise 5 10. Glazing and visibility 5 11. Lamp/signal requirements 5 12. General provisions 5 Australian Design Rules (information and listing) 5 ADR 1/.. Reversing lamps 6 ADR 2/.. Side door latches and hinges 6 ADR 3/.. Seats and seat anchorages 6 ADR 4/.. Seatbelts 7 ADR 5/.. Anchorages for seatbelts 8 ADR 6/.. Direction indicator lamps 9 ADR 8/.. Safety glazing material 10 ADR 10/.. Steering column 11 ADR 11/.. Internal sun visors 11 ADR 13/.. Installation of lighting and light signalling devices 11 ADR 14/.. Rear vision mirrors 11 ADR 18/.. Instrumentation 12 ADR 21/.. Instrument panel 12 ADR 22/.. Head restraints 13 ADR 23/.. Passenger car tyres 13 ADR 25/.. Anti-theft lock 14 ADR 28/.. External noise of motor vehicles 14 ADR 29/.. Side door strength 14 Contents Description Page Number ADR 30/.. Diesel engine exhaust smoke emissions 15 ADR 31/.. Hydraulic brake systems for passenger cars 15 ADR 34/.. Child restraint anchorages and ttings 16 ADR 37/.. Emission control for light vehicles 16 ADR 42/.. General safety requirements (includes the following) 17 Bonnet latching 17 Diesel engine anti start locking device 17 Steering system 17 Standard controls for automatic transmissions 17 Electrical wiring, connections and installations 17 Exhaust outlets 17 External or internal protrusions 17 Field of view 18 Wheel guards (mudguards) 18 Brake tubing and brake hose 19 Reverse gear 19 Television and visual display units 19 Windows and ventilation 19 Power Operated Windows 19 Warning devices audible 19 Demisting of windscreens 19 Windscreen wipers and washers 19 ADR 43/.. Vehicle conguration and marking 19 ADR 46/.. Headlamps 20 ADR 47/.. Retro-reectors 20 ADR 48/.. Rear registration plate illuminating devices 20 ADR 49/.. Front and rear position (side) lamps stop lamps and end outline marker lamps 21 ADR 51/.. Filament globes 21 ADR 60/.. Centre high-mounted stop lamp 21 ADR 61/.. Vehicle marking 22 Dynamic Occupant Protection 22 Airbags 22 Gas Discharge Headlamps 22 DEFINITION OF AN INDIVIDUALLY CONSTRUCTED VEHICLE Individually Constructed Vehicles (ICV) are vehicles where the body and chassis are new, however the sub assemblies and components used may be derived from other production vehicles and need not be new. Most ICVs are passenger car type vehicles which includes sedans, station wagons, coupes, and tourers. An ICV is a one-off vehicle. If production of more than one vehicle per year is proposed, DTEI should be consulted because construction and compliance of the vehicles may then be administered under the Commonwealth Government Department of Transport and Regional Services, Low Volume Scheme. An Individually constructed vehicle is a new vehicle that is not a production vehicle, a modied production vehicle or a production vehicle which has had the body or chassis replaced. ENGINEERING REQUIREMENTS Design & Engineers responsibility All aspects of design including compliance with Australian Design Rules, Regulations, compatibility of engine with other vehicle components, steering, braking, handling and drivability will remain the responsibility of the Engineer submitting the Engineering Report. Inspection Procedure It is recommended that the vehicle be inspected by the Engineer at the following stages: a. At completion of the chassis prior to the tting the body or any other component which may obstruct inspection of chassis welds etc. b. At some intermediate stage of construction. c. After completion of the vehicle but prior to presentation for the full roadworthy inspection by DTEI. Engineers Report All aspects of design and components used must be fully addressed in an Engineering Report prepared for the vehicle. Letter of Conformity As assurance that the vehicle has been inspected by the Engineer and the vehicle conforms with the Engineering Report, a Letter of Conformity must be submitted prior to the vehicle being inspected by DTEI. The Letter of Conformity must include the following: name and address of the owner make and type of vehicle chassis number or VIN engine number dates of inspection during construction a statement to the effect that the above vehicle has been constructed in accordance with the Engineering Report Number .. Dated .. signature of the Chartered Professional Engineer dated and signed. Finding an Engineer A list of appropriately qualied and experienced engineers involved in this type of work in South Australia is available on request from DTEI. RECOMMENDED CONSTRUCTION & APPROVAL PROCESS a. Consult the Chartered Professional Engineer as to the acceptability of the vehicles proposed construction and revise if necessary. b. Obtain conrmation from the engineer that the proposed vehicle will comply with the appropriate ADRs and Regulations. This conrmation usually takes the form of an Engineering Report and enables construction of the vehicle to commence, however see point d. c. Complete the Application to Build an Individually Constructed Vehicle form and submit it to Vehicle Standards together with the Engineering Report and any other relevant documentation. d. If the proposal is acceptable then Vehicle Standards will then issue a Statement of Requirements (SOR). If the proposal is not acceptable or further information is required Vehicle Standards will contact the applicant in writing. This should be done as early in the process as possible because the SOR or Regulation changes may inuence the design. e. Following the completion of construction, the vehicle must undergo inspection and performance testing by the engineer to ensure that the vehicle meets all applicable standards, Regulations and to verify that its safe operation on the road is ensured. The results of all performance tests must be recorded and retained by the Engineer. The Engineer must then complete a Letter of Conformity to conrm that the vehicle has been constructed in accordance with the Engineering Report. f. Following the Letter of Conformity and the receipt of a Statement of Requirements from Vehicle Standards the vehicle can be booked in for a full roadworthy inspection. If the vehicle fails inspection, the relevant issues must be addressed and the vehicle submitted for inspection at a later date. When the vehicle passes inspection it can then be registered and will be issued with an Exemption From the Fitting of a Compliance Plate and a South Australian I.D. Label which will identify the vehicle. APPLICATIONS Except for those aspects which can only be determined after construction is completed, the application prepared by the Chartered Professional Engineer and submitted to DTEI must give full design details relating to the following: 3 1. ENGINE & DRIVELINE Engine make, size and number of cylinders Any changes from standard specications Power and torque specications Turbocharger or supercharger (if tted) Drive-line and differential Gearbox and transmission Fuel system (i.e. petrol, diesel, LPG). Engine Selection Engine power and torque must be compatible with the driveline, structural and braking components. For details relating to emission control refer to ADR 37/.. 2. BRAKES System (refer to ADR 31/.. and 42/..) Type (i.e. disc, drum) Brake balance. Vehicle Braking Tests to show compliance with ADR 31/.., or equivalent, must be conducted and submitted prior to presentation of the vehicle for nal inspection. Refer to Engineering Instruction Number 4 - Brake System Test Procedure or refer to ADR 31I.. Brake Balance Tests to ensure correct brake balance must be conducted and submitted prior to presentation of the vehicle for nal inspection. 3. WHEELS & TYRES Size, speed and load ratings, carcass construction (refer to ADR 23/..) 4. AXLES & SUSPENSION Type and make of axles (front and rear) Method of attachment Strength at 1g braking and 3g bump Width of axles between wheel mounting anges Bump clearance Ground clearance (refer to ADR 43/..) Track (front and rear). Wheel Track Wheel track is the distance measured across an axle between the centre line of the left wheel and the centre line of the right wheel. Where standard axles are used the wheel track will be based on the maximum allowable wheel track for the vehicle for which the axle was designed. Alternatively an Engineering Report showing that the wheel track is within the design capabilities of the components being used and that the track does not have any adverse affect on vehicle handling and/or steering. Where non-standard components are tted the wheel track will be assessed, determined and justied by the Engineer. 5. STEERING Steering geometry Steering column (refer to ADR 10/..) Anti-theft locks (refer to ADR 25/..). Components Steering components are not permitted to be welded or heated unless an Engineering Report is submitted to DTEI in accordance with Engineering Instruction Number 5 - Heating and Welding of Steering Components. All newly manufactured steering components must be identied and a full description of manufacture including drawings must be presented, as well as an assessment and statement of suitability by the Engineer. Geometry Test results of a subjective test which show handling characteristics must be submitted prior to presentation of the vehicle for nal inspection. Refer to Lane Change Manoeuvre Test Procedures MR 807 (MR 807). In addition the Engineer should show that the vehicle does not demonstrate excessive bump steer throughout the operating range of the front suspension. 6. CHASSIS OR FRAME Style and type Material and strength Mounting of body to chassis/frame Beaming and torsional rigidity Wheel base. Beaming & Torsional Rigidity The beaming and torsional rigidity is usually evaluated on the composite chassis/frame and body. An Engineering Report on the beaming and torsional rigidity to a procedure acceptable to DTEI may be required. Refer to Torsional Rigidity and Beaming Stiffness Test Procedures (MR 816). 7. BODY Style and type Material Position and accessibility of foot controls Door strength (refer to ADR 29/..) Door latches and hinges (refer to ADR2/..) Mudguards (refer to ADR 42/..) Engine bonnet (refer to ADR 42/..) Driver eld of view (refer to ADR 42/..) Primary vision area (refer to ADR 8/..) External and internal projections (refer to ADR 42/..) Internal sun visors (refer to ADR 11/..) Location and visibility of instruments (refer to ADR 18/..) Instrument panels (refer to ADR 21/..). Body Design It is essential to carefully examine the requirements of driver eld of view, primary vision area, windscreen wipers and washers and mudguards when designing the body shell of the vehicle. 4 Occupant Protection The following ADRs apply to passenger car type vehicles: ICVs are not required to prove compliance with these ADRs but should be constructed to comply with the intent of these ADRs and offer the best occupant protection possible. See Dynamic Occupant Protection on page 22. 8. SEATS & Seatbelts Type and number of seats Size and height of seats Seat anchorages (refer to ADR 3/..) Seatbelts (refer to ADR 4/..) Seatbelt anchorage points (refer to ADR 5/..) Child restraint anchorages (refer to ADR 34/..) Head restraints (refer to ADR 22/..) Instructions for the use of Seatbelt Assemblies (refer to ADR 4/..) Instructions for the use of Child Restraint Anchorages (refer to ADR 34/..). 9. EMISSIONS & NOISE ICVs constructed before 31/12/03 must comply with ADR 37/00 Emission Control for Light Vehicles. ICVs constructed after 31/12/03 must comply with ADR 37/01 Emission Control for Light Vehicles Where satisfactory evidence can be provided that vehicle construction commenced prior to 31/12/03 DTEI may accept compliance with ADR 37/00. ADR 37/.. includes exhaust emissions, evaporative emissions, crankcase gasses and petrol ller inlets. Diesel engine smoke (refer to ADR 30/..) External noise (refer to ADR 28/..). 10. GLAZING & VISIBILITY Glazing material (refer to ADR 8/..) Rear vision mirrors (refer to ADR 14/..) Demisting of windscreens (refer to ADR 42/..) Windscreen wipers and washers (refer to ADR 42/..) Driver eld of view (refer to ADR 42/..) Primary vision area (refer to ADR 8/..) Window tinting refer to DTEI Window Tinting for your Motor Vehicle (MR 430) Centre high-mounted stop lamp (refer to ADR 60/..) . 11. LAMP/SIGNAL REQUIREMENTS Headlamps (refer to ADR 46/..) Front position lamps (refer to ADR 49/..) Rear position lamps (refer to ADR 49/..) Rear registration plate illuminating device (refer to ADR 48/..) Retro-reectors (refer to ADR 47/..) Hazard warning signals (refer to ADR 13..) Globes (refer to ADR 51/..) Reversing lamps (refer to ADR 1/..) Direction indicator lamps (refer to ADR 6/..) Centre high - mounted stop lamp (refer to ADR 60..). 12. GENERAL PROVISIONS Turning circle (refer to ADR 43/..) Controls (refer to ADR 42/..) Electrical wiring (refer to ADR 42/..) Exhaust outlets (refer to ADR 42/..) Ventilation (refer to ADR 42/..) Reverse gear (refer to ADR 42/..) Engine number (refer to ADR 43/..) Warning device (refer to ADR 42/..) Registration plates and labels (refer to ADR43/..) Vehicle identication number (refer to ADR 43/..). Australian Design Rules The ADRs have been developed to provide detailed performance specications for safety standards in vehicles with the objective of reducing: the frequency of accidents the severity of occupant injury when accidents do occur the adverse impact of noise, smoke and gaseous emissions on the community and the environment. Components used in constructing an ICV may be taken from a vehicle which complies with the relevant ADRs provided that details of the make, model and date of manufacture of the vehicle concerned are quoted. Items which are not identical to those from a complying vehicle may be accepted subject to an engineering evaluation. Following is a resume of the relevant ADRs. The requirements quoted are only an abbreviation of compliance required for a vehicle to meet the intent of the specic ADRs. Every ICV is required to comply with the intent of the relevant ADRs listed below: ADR number & title: 1/..Reversing Lamps 2/..Side Door Latches & Hinges 3/..Seat Anchorages 4/..Seatbelts 5/..Anchorages for Seatbelts 6/..Direction Indicator Lamps 8/..Safety Glazing Material 10/..Steering Column 11/..Internal Sun Visors 13/..Installation of Lighting & Light-signalling Devices 14/..Rear Vision Mirrors 18/..Instrumentation 21/..Instrument Panel 5 ADR 69/.. Full Frontal Impact Occupant Protection ADR 72/.. Dynamic Side Impact Occupant Protection ADR 73/.. Offset Frontal Impact Occupant Protection 22/..Head Restraints 23/..Passenger Car Tyres 25/..Anti-Theft Lock 28/..External Noise of Motor Vehicles 29/..Side Door Strength 30/..Diesel Engine Exhaust Smoke Emission 31/..Hydraulic Brake Systems for Passenger Cars 34/..Child Restraint Anchorages and Child Restraint Anchor Fittings 37/..Emission Control for Light Vehicles 42/..General Safety Requirements contains information on the following: 5. Bonnet Latching 6. Diesel Engines (anti-start locking device) 7. Controls 9. Electrical Wiring, Connections & Installations 10. Exhaust Outlets 11. External or Internal Protrusions 12. Field of View 14. Wheel Guards (Mudguards) 15. Brake Tubing & Brake Hose 16. Reverse Gear 18. Television & Visual Display Units 19. Windows & Ventilation 20. Warning Devices Audible 23. Demisting of Windscreens 24. Windscreen Wipers & Washers 25. Tyre & Rim Selection 43/..Vehicle Conguration & Marking 45/..Lighting & Light Signalling Devices Not Covered By ECE Regulations 46/..Headlamps 47/..Retro-reector 48/..Rear Registration Plate Illuminating Device 49/..Front & Rear Position (Side) Lamps, Stop Lamps & End Outline Marker Lamps 51/..Filament Globes 60/..Centre High-Mounted Stop Lamp 61/..Vehicle Marking 62/..Mechanical Connections Between Vehicles 69/..Full Frontal Impact Occupant Protection 72/..Dynamic Side Impact Occupant Protection 73/..Offset Frontal Impact Occupant Protection ADR 1/.. REVERSING LAMPS Intent To specify the photometric requirements for reversing lamps which will warn pedestrians and other road users that the vehicle is about to move or is moving in the reverse direction and which during the hours of darkness will aid the driver in reversing manoeuvres. Requirements ADR 1/.. species that the colour of the light emitted shall be white. ADR 13/.. species that: there shall be one or two reversing lamps at the back of the vehicle positioned not less than 250 mm nor more than 1200 mm above the ground if only one lamp is tted it must be positioned on the drivers side of the vehicle the lamp or lamps shall only light up if the reverse gear is engaged and either the ignition switch is in the on position or the engine is running the lamps shall be visible at 15 degrees upward and 5 degrees downward, 45 degrees to the right and to the left if there is only one lamp or 45 degrees outwards and 30 degrees inward if there are two lamps may not be grouped, combined or reciprocally incorporated with any other rear lamps. ADR 2/.. SIDE DOOR LATCHES & HINGES Intent To specify requirements for side door retention components including latches, hinges and other supporting means to minimise the likelihood of occupants being thrown from a vehicle as a result of impact. Requirements Each door latch and striker assembly shall be provided with two positions consisting of a fully latched position and a secondary latched position which provide both longitudinal and transverse restraint. Each door shall be equipped with a locking mechanism with an operating means in the interior of the vehicle. When the locking mechanism is engaged, the door handles on the outside of the front doors and all door handles on the rear doors shall be inoperative. ADR 3/.. SEATS & SEAT ANCHORAGES Intent To specify requirements for seats, their attachment assemblies, and their installation to minimise the possibility of occupant injury due to forces acting on the seat as a result of vehicle impact. Requirements Each seat shall be capable of withstanding a load, equivalent to: twenty times the mass of the entire seat, when applied in either a forward or rearward direction a 530Nm moment about the seating reference point applied to the upper cross-member in the rearward direction where a seat must hinge or fold to permit access to or egress from another seat the seat shall be tted with a self-locking device for restraining the seat or seat back The release control shall be readily accessible to both the occupant of that seat and the occupant of a seat immediately behind that seat where there are rear seating positions; the rear surfaces of the front seats that can be contacted by a person in a rear seat must be padded in accordance with ADR 3/02. Alternative criterion Seats anchored through vehicle oors made from sheet metal can be adequately secured by using 8 mm bolts and 40x40x3 mm steel backing plates. 6 The upper anchorage sash location point shall be at least 140 millimetres from the seating reference plane (Refer to ADR 5/..) The lower anchorages must be on opposite sides of the centre line of the seating position and located within the shaded area as shown in Figure 2. A minimum of four anchorage bolts per seat, for single seats must be provided. For double and triple seats, additional anchorage bolts may be required. The corners of backing plates shall have a minimum radius of 5 mm and the edges adjacent to the sheet metal must be chamfered. ADR 4/.. SEATBELTS Intent To specify the requirements for seatbelts to restrain vehicle occupants under impact conditions, to facilitate fastening and correct adjustment, to assist the driver to remain in the seat and thus maintain control of the vehicle in an emergency situation, and to provide protection against ejection in an accident situation. Requirements All outboard seating positions shall be tted with a lap/sash seatbelt which incorporates a dual lock emergency locking retractor mechanism. All inboard seating positions shall be tted with either a lap belt or a lap-sash belt. Only new seatbelts, complying with Australian Standard 2596 - Seatbelt Assemblies for Motor Vehicles or AS E35 Pt 1 - 1970 - Seatbelt Assemblies for Motor Vehicles, or any other approved standard accepted as equivalent, can be tted. Instructions for use of seatbelt assemblies shall be included in the vehicle handbook, or otherwise supplied with the vehicle. The instructions shall be in accordance with the ADR. LOCATION - Seatbelt ANCHORAGES Alternative criterion 7 Anchorages must be provided to suit the seatbelts required by ADR 4/.. They must be positioned so that the seatbelt webbing is able to function properly, without rubbing against any sharp edges. The upper anchorage is to be located within the shaded area shown in Figure 1. ADR 5/.. ANCHORAGES FOR SEATBELTS Intent To specify the requirements for anchorages for seatbelt assemblies so that they may be adequately secured to the vehicle structure or seat and will meet comfort requirements in use. Requirements A report prepared by a Chartered Professional Engineer which demonstrates compliance with ADR 5/.. must be presented or the anchorages shall be designed, located and constructed so that they meet with the alternative criterion. Because seatbelts are generally made to standard lengths it is essential that the lower anchorages be placed in a position behind the seat so as to allow for the buckle of the buckle strap or stalk to be located at the side of the hip of a seated occupant. The buckle must not be allowed to rest on the seated persons abdomen. The optimum distance between the lower anchorages of a seatbelt is from 250 mm to 350 mm with the minimum distance being 165 mm. The lower seatbelt anchorages must not be superimposed i.e. each seatbelt must be anchored by a separate bolt. Anchorages provided for different seating positions are to be separated by at least 200 mm. Construction - seatbelt anchorages All anchorages must be able to withstand a force of at least 10 kN applied for not less than 30 seconds along the direction of the line of the seatbelt. Under test conditions some deformation is permitted but the anchorage must not pull away from the structure. Proof of the strength of anchorages shall be by calculation, physical testing or where applicable in accordance with the alternative criterion. Alternative criterion When anchorages are located in vehicle oors, parcel shelves or other areas of the vehicle made from sheet metal, steel backing plates (approximately 75 x 50 x 3 mm) are normally adequate. The size of the seatbelt anchorage backing plate depends upon the strength of the material to which the anchorage is fastened. The following must be taken into consideration when determining the size of the plate: a. the thickness of the oorpan, upperbody or pillar material b. the shape of the oorpan, upperbody or pillar, whether at, corrugated, uted, curved box or composite section c. the type of material from which the oorpan, upperbody or pillar has been constructed (e.g. steel, aluminium). The corners of all backing plates are to have a 5 mm minimum radius and edges adjacent to the body are to be chamfered. 8 Individually Constructed Vehicles MARCH 2007 The anchor bolts must be tightened to the correct tension using a torque wrench. The bolt must fully engage all the thread of the nut and this may mean that a longer bolt than that supplied with the seatbelt kit is required. Fine threaded 7/16 (11 mm) mild steel bolts are usually used. Anchorages must not be tted through wood or where wood or other non- metal material is sandwiched between steel. Do not t anchorages in aluminium or breglass panels without obtaining specic approval from the Engineer. Anchorages and ttings must be protected from corrosion by suitable paint or other anti-corrosive substance. The general construction of anchorages is shown in Figures 3 and 4 below. ADR 6/.. DIRECTION INDICATOR LAMPS Intent To specify the photometric and eld of view requirements for direction indicators which will provide adequate warning to other road users of the intention to perform a turning manoeuvre. Requirements The colour of the light emitted shall be amber The light emitted from the front and rear lamps shall be visible at all angles between 45 degrees inboard and 80 degrees outboard and 15 degrees above and below the horizontal within these boundaries The mounting and visibility of indicator lamps is shown in Figure 5. ADR 13/.. SPECIFIES THAT: there shall be: i) two front direction indicator lamps ii) two rear direction indicator lamps iii) two repeating side direction indicator lamps. the outside edges of the lamps at the front and rear shall not be more than 400 mm from the outer edge of the vehicle the distance between the inner edges of the lamps at the front and rear shall be not less than 600 mm the side direction indicator lamps shall not be more than 1800 mm from the front of the vehicle (the side lamps may be combined with the front lamps) the lamps at the front and rear shall be not less than 350 mm nor more than 1500 mm above the ground the side lamps shall be not less than 500 mm nor more than 1500 mm above the ground the direction indicator lamps shall switch on independently of any other lamps all direction indicator lamps on one side of the vehicle shall be switched on and off by means of one control and shall ash in phase at a rate of between 60 and 120 times per minute the vehicle shall be tted with audible and/or visible indicator for the direction indicator lamps the illuminating surface of the front direction indicator lamps must not be less than 40 mm from the illuminating surface of the dipped-beam headlamps or fog lamps if any. 9 Intent To specify the performance requirements of material used for external or internal glazing in motor vehicles which will ensure adequate visibility under normal operating conditions with minimum obscuration when shattered, and will minimise the likelihood of serious injury if a person comes in contact with the broken glazing material. Requirements Any glass used in windscreens, windows or interior partitions shall be of safety glass complying with one of the approved standards. All glass shall carry an indelible mark or marks visible when the glass is tted in the vehicle. The mark or marks shall identify the type of glass and the relevant standard to which the glass conforms. The windscreen used shall meet with the primary vision area requirements which allows an average driver to see: upwards at 10 degrees to the horizontal downwards to the roadway 11 metres ahead of the vehicle 56 degrees to the left 15 degrees to the right of a horizontal line passing through the right eye of the driver which is parallel to the vehicle centre line. The primary vision area requirements are shown in Figures 6 and 7. ADR 8/.. SAFETY GLAZING MATERIAL The Visual Light Transmission of a windscreen in the Primary Vision Area (as dened in ADR 8/..) must not be less than 75%. It is permissible to have a narrow tinted band across the top of the windscreen which is outside the Primary Vision Area. Window tinting For Information regarding the legal requirements for window tinting refer to DTEI Window Tinting for your Motor Vehicle (MR 430).
10 Individually Constructed Vehicles MARCH 2007 ADR 10/.. STEERING COLUMN Intent To minimise crushing or penetrating injuries to drivers due to the steering column as a result of frontal impact. Requirements The steering column assembly used in a one-off vehicle shall be identical to one used in a vehicle approved to ADR 10/.. The steering column assembly comprises the basic steering mechanism, the steering wheel, the associated horn actuating mechanism and trim hardware. The steering shafts and associated components between the steering column and steering box may also affect compliance with ADR 10/.., consequently the manner of installation is subject to approval. Optional steering wheels tested to ADR requirements on the column assembly will be accepted. A motor vehicle must not have a Steering Control Effort in excess of 250 N when the vehicle is operating at a speed not greater than 10 km/h. The Steering Control Effort is the force exerted by the driver of the vehicle measured at the rim of the steering wheel with any and all power assistance devices operating and no failures being present in the system. ADR 11/.. INTERNAL SUN VISORS Intent To specify requirements for internal sun visors to reduce the injury potential of internal sun visors and the adjacent vehicle structure. Requirements If sun visors are tted to the vehicle they shall be constructed of, or covered with, energy absorption material. Any rigid structure required to support the sun visor or maintain its shape shall be of such dimensions as to limit the likelihood of injury to the head on impact. Any rigid material edge shall have a radius of not less than 3 mm. ADR 13/.. INSTALLATION OF LIGHTING AND LIGHT-SIGNALLING DEVICES Intent To ensure that the installation of lighting and light-signalling devices on the vehicle is such that the effective operation of these devices is not impaired. Requirements Main-beam headlamps (ADR46/..) Dipped-beam headlamps (ADR 46/..) Front fog lamps (ADR 50/..) Gas discharge headlamps (ADR 77/..) Reversing lamps (ADR 1/..) Direction indicator and hazard warning lamps (ADR 6/..) Stop lamps (ADR 49/..) Rear registration plate illuminating device (ADR 48/..) Rear fog lamps (ADR 52/..) Front position (side lamps) (ADR 49/..) Rear position (side lamps) (ADR 49/..) Parking lamps (ADR 49/..) Retro-reectors (ADR 47/..) Centre high-mounted stop lamp (ADR 49/.. or ADR 60/..) Cornering lamp (ADR 45/..). Hazard warning signal lamps The signal shall be given by simultaneous operation of the direction indicator lamps and shall be operated by means of a separate control enabling all the direction indicator lamps to ash in phase. A tell-tale shall be tted. The signal shall be able to function even if the device which starts or stops the engine is in a position which makes it impossible to start the engine (ignition off). ADR 14/.. REAR VISION MIRRORS Intent To specify requirements for rear vision mirrors to provide the driver with a clear and reasonably unobstructed view to the rear. Requirements Drivers Side Mirror An external rear vision mirror shall be installed on the drivers side of the vehicle and must provide the driver with a view of a level road surface 11 metres behind the drivers eyes and 2.4 metres out from the plane represented by the drivers side of the vehicle. The mirror and mounting shall be free of sharp points or edges. The mirror shall be adjustable from the drivers seating position. The mirror may have either a at or convex reecting surface. The average radius of a convex mirror is not to be less than 1,200 mm. Internal Rear Vision Mirror An internal rear vision mirror shall also be installed except where the design of the motor vehicle does not provide for internal rear vision. Field of View an internal mirror shall provide the driver with a view to the rear with an included angle of 20 degrees in the horizontal plane (between left and right) and sufcient vertical angle to provide a view of the road surface 61 metres behind the vehicle extending to the horizon. The line of sight may be partially obscured by seated occupants or by head restraints. Internal rear vision mirrors tted to the vehicle shall have at reecting surfaces. The internal rear vision mirror mounting shall provide a stable support for the mirror, and shall provide for adjustment by tilting in horizontal and vertical directions. If the mirror is subjected to an impact, the mounting shall deect, collapse or break away without leaving sharp edges. Passenger Side Rear Vision Mirror If the design of the vehicle does not permit an adequate eld of view from the internal mirror an external rear vision mirror shall be installed on the passengers side of the vehicle. The passenger side mirror need not be 11 adjustable from the drivers seating position, but shall be capable of adjustment by tilting in both horizontal and vertical directions. The mirror can be at or convex. The average radius of a convex mirror is not to be less than 1,200 mm. ADR 18/.. INSTRUMENTATION Intent To specify requirements for the provision and location of certain visual indicators. Requirements A speedometer shall be tted which indicates the vehicle speed in kilometres per hour. A speedometer shall not read less that the actual speed of the vehicle. The speedometer must be installed so that its indication is readily visible to the driver when seated in the normal driving position. An odometer shall be tted which shall indicate the distance travelled in one kilometre units (or less) from 1 to 999,999 kilometres with an accuracy of +/- 4%. The display of information presented by the visual indicators in the following list shall, if tted to the vehicle, meet the location requirements shown in Figure 8. a. Speedometer b. Direction indicator tell-tale lamp or lamps c. High beam indicator d. Tachometer e. Oil pressure indicator e. Odometer i. Water temperature indicator f. Service brake failure indicator lamp j. Battery charge failure indicator g. Stop lamp failure indicator k. Fuel level indicator h. Oil temperature indicator l. Parking brake indicator lamp The visual indicators shall be totally visible to the driver with the steering wheel in the straight ahead position, and with the direction indicator lever in the neutral position, (the steering wheel rim and its supporting arms and attachment do not constitute obstructions). ADR 21/.. INSTRUMENT PANEL Intent To specify requirements for the instrument panel to reduce its injury potential to occupants on impact. Requirements The area of the instrument panel that is within the Head Impact Area when impacted, by a given head form and velocity, the deceleration of the head form shall not exceed 80 times the acceleration due to gravity continuously for more than 3 milliseconds. Refer to ADR 69/.. for vehicles incorporating an inatable supplementary restraint system (air bag). Alternatively proof of compliance with the alternative criterion. 12 Individually Constructed Vehicles MARCH 2007 ADR 22/.. HEAD RESTRAINTS Intent To specify requirements for the design of head restraints so as to limit the severity of injury in the event of rear-end impacts (whiplash) and to ensure that the head restraints cannot be adjusted too low. Requirements Head restraints are to be constructed and contoured to decelerate horizontal movements of the head without concentrations of load on it. Head restraints shall be provided for each of the two front outboard seating positions. The head restraints must be mounted on, or be integral with the seat backs. They may be provided with adjustable mounting but the upper boundary of the impact surface shall not be lower than 700 mm above the Seating Reference Point refer page 7. The width of each head restraint shall not be less than 250 mm for use with bench seats and not less than 170 mm for use with individual seats. The head restraint shall not measure less than 115 mm between upper and lower boundaries. Alternative criterion The areas not shown as exempt in Figures 9 and 10 must be covered with high density energy absorbing material. ADR 23/.. PASSENGER CAR TYRES Intent To specify requirements of strength, construction and standard pressure/ load relationships for passenger car tyres of particular size designations. Requirements Each tyre shall be conspicuously labelled on both sidewalls with the following information: tyre size designation speed category tyre carcass construction maximum load rating or load index identication of the tyre manufacturer date of manufacture word tubeless if applicable. The labelling shall consist of permanently moulded characters at least 3.8 mm high and 0.25 mm deep if below the background surface, or at least 0.4 mm outstanding, if above the background surface. Each tyre tted to the vehicle shall incorporate at least four treadwear indicators approximately equally spaced, each of which provides a visual indication that the tread in its vicinity has a minimum groove depth of 1.25 mm. 13 ADR 25/.. ANTI-THEFT LOCK Intent To specify requirements for a lock to inhibit unauthorised use of the vehicle and to minimise possibility of inadvertent application of steering locks to the anti-theft position when the vehicle is in motion. Requirements A key operated protective device shall be tted to the vehicle to prevent the engine from being started and to prevent the vehicle from being either steered, driven or moved forward under its own power. This protective device and the components on which it operates, shall be so designed that it cannot rapidly and without attracting any attention, be opened, rendered ineffective, or destroyed. The protective device shall be such that it excludes any risk of accidental operation while the vehicle is in motion which is likely to compromise safety. i.e. It shall not be possible to activate protective devices acting on the steering, transmission or gear shift control without rst setting the engine control to a stop condition. It shall not be possible to activate the motive power of the vehicle by normal means until the protective device has been deactivated. For more information refer to ADR 25/.. Anti-theft Lock. Alternative criterion The vehicle shall have a key operated lock which provides: an engine-on position which permits the normal functioning of the engine an engine-off position which prevents the normal functioning of the engine an anti-theft position which prevents the normal functioning of the engine and also inhibits unauthorised use of the vehicle. It shall not be possible to adjust the lock from the engine-on position to the anti-theft position without passing through the engine-off position. When the key is removed the lock shall be in the anti-theft position and it shall be impossible either to steer the vehicle or to engage the forward drive gears or to release a brake without removal or destruction of the device. ADR 28/.. EXTERNAL NOISE OF MOTOR VEHICLES Intent To specify limits for external noise from motor vehicles in order to limit the contribution of motor trafc to community noise. Requirements The vehicle when tested in accordance with the requirements of ADR 28/.. the sound level measured shall not exceed 77 dB(A) for the vehicle in motion test and 90 dB(A) for the stationary test. Alternative criterion Proof of compliance demonstrated by a stationary exhaust noise test in accordance with the National Road Transport Commission National Stationary Exhaust Noise Test Procedures for In-Service Motor Vehicles ADR 29/.. SIDE DOOR STRENGTH Intent To specify strength and stiffness requirements for side doors of passenger cars which can be used for occupant access to reduce intrusion into the passenger compartment as a result of side impact. Requirements An Engineering Report which demonstrates compliance with ADR 29/.. shall be submitted. Alternative criterion Proof of compliance with the technical requirements of S3 and S4 of FMVSS 214 35 F.R. 16801, October 30, 1970 Side Door Strength Passenger Cars as amended by FMVSS 214-58 FR 14169 is required to be submitted. 14 Individually Constructed Vehicles MARCH 2007 ADR 30/.. DIESEL ENGINE EXHAUST SMOKE EMISSIONS Intent To limit the opacity of diesel engine exhaust smoke emissions. Requirements A diesel engine tted to an ICV must comply with ADR 30/.. Smoke Emission Control for Diesel Vehicles. ADR 30/.. refers to ECE Regulation 24 Uniform Provisions Concerning: i. the approval of compression ignition (C.I.) engines with regard to the emission of visible pollutants ii. the approval of motor vehicles with regard to the installation of C.I. engines of an approved type iii. the approval of motor vehicles equipped with C.I. engines with regard to the emission of visible pollutants by the engine iv. the measurement of power of C.I. engine. The diesel engine shall have afxed to it a durable, legible label which indicates that the engine was manufactured to comply with ADR 30/... The label shall be plastic or metal and shall be bonded, welded, riveted or otherwise securely attached to a part of the engine necessary for normal engine operation and not normally requiring replacement during engine life. The label shall be in a position in which it can be read after installation in the vehicle. The engine, as installed in the vehicle, shall be adjusted to the manufacturers specications. Any cold starting device shall be designed so that it cannot be brought into or retained in operation when the engine is running normally. The vehicle shall be equipped with a stopping device which is operated by the vehicles ignition switch. ADR 31/.. HYDRAULIC BRAKE SYSTEMS FOR PASSENGER CARS Intent To ensure safe braking under normal and emergency conditions for vehicles equipped with hydraulic service brakes. Requirements If the vehicle has a hydraulic braking system it shall have: a control for the service brake system which it is readily accessible to the driver in the normal driving position a parking brake system such that in the applied position retention is effected by mechanical means. The control by which the system is actuated is to be readily accessible to the driver in the normal driving position one or more service brake failure indicator lamps and a parking brake indicator lamp. An Engineering Report which demonstrates compliance with ADR 31/.. shall be submitted or alternatively, tests should be conducted which demonstrate that the vehicle conforms with the alternative criterion. Alternative criterion Fade Test With the vehicle unladen, fteen deceleration modes must be conducted in accordance with ADR 31/00 but from a minimum initial speed of 60km/h, such that the sustained deceleration is not less than 4.5 m/s2 for each mode and the distance between successive brake applications is not more than 250 metres or the maximum interval between successive applications is not more than 25 seconds. The pedal effort as specied in ADR 31/00 must not be exceeded. Refer to DTEI Brake System Test Procedure (MR132). Effectiveness Test Immediately on completion of the Fade Tests, two Effectiveness Tests must be conducted in accordance with item 7 of ADR 31/00 (i.e. Third Effectiveness Test). If the instantaneous deceleration is measured instead of the average deceleration, the deceleration shall not be less than 0.89g for any one of the two stops. If the above test requirements are met with a pedal effort of less that 150 Newtons the Minimum Pedal Effort Test in accordance with the ADR 31/00 must be conducted. Refer to DTEI Brake System Test Procedure (MR 132). 15 ADR 34/.. CHILD RESTRAINT ANCHORAGES & FITTINGS Intent To specify requirements for child restraint anchorages and child restraint anchor ttings to provide for the connection of standard attaching clips so that child restraints may be adequately secured to the vehicle. Anchorages Each rear seating position must have either a Child Restraint Anchor Fitting or a mounting point for one. The Child Restraint Anchor Fitting is the attachment point for the Attaching Clip of a child restraint system and is usually bolted or welded to the structure of the vehicle. Each anchorage shall be so designed and located that: a. no items need to be removed to gain access to the anchorage, other than closure plugs, and items that are removable without the use of tools b. clearance is provided to allow the installation of child restraint anchor tting and for the latching and unlatching of the attaching clip to the child restraint anchor tting without the use of tools c. it is within 40 mm of the centre line of the seating position d. it is rearward of the seat backrest e. information including either a photograph or a diagram regarding the location of each Child Restraint Anchorage shall be specied in the vehicle handbook or otherwise supplied with the vehicle. The information shall include: WARNING: Child restraint anchorages are designed to withstand only those loads imposed by correctly tted child restraints. Under no circumstances are they to be used for adult seatbelts or harnesses. Details on the thickness (and number) of spacers required at each Child Restraint Anchorage location and the correct method of installation of Child Restraint Anchor Fitting(s). See Figure 11. Construction Child Restraint Anchorages All anchorages are to be tested simultaneously and each anchorage must be able to withstand a force of at least 3.4 kN. The direction of the test load shall be within 20 degrees of the design line of action of the child restraint anchorage tting and not more than 5 degrees to the left or right of the longitudinal axis of the vehicle. Under test conditions, some deformation is permitted, but the anchorage must not pull away from the structure. Proof of the strength of anchorages shall be by calculation, physical testing or where applicable in accordance with the alternative criterion. Alternative Criterion Child Restraint Anchorages located through a sheet metal section of the vehicle body such as the rear parcel shelf can be constructed by using 50 x 50 x 3 mm steel backing plates, or plates of equivalent size and stiffness with a nut permanently attached to the underside of the plate. The corners of backing plates shall have a minimum radius of 5 mm and the edges adjacent to the sheet metal shall be chamfered. ADR 37/01 EMISSION CONTROL FOR LIGHT VEHICLES Intent To limit fuel evaporative emissions and exhaust emissions from motor vehicles in order to reduce air pollution, and to require new vehicles to be manufactured to operate on unleaded petrol. Requirements Vehicle to be tested in accordance with the requirements of ADR 37/01 or evidence to be submitted to show that the vehicle complies with the alternative criterion. Alternative criterion The engine tted to the vehicle shall be designed to use unleaded petrol or Liqueed Petroleum Gas (LPG) as a fuel. The engine must remain standard as manufactured and incorporate all design features and components originally tted to that engine. In addition, the vehicle is required to retain any other associated components of the system such as the catalytic converter. 16 Individually Constructed Vehicles MARCH 2007 In the case of vehicles operating on petrol a label of durable material with the words UNLEADED PETROL ONLY in letters at least 6 mm high shall be permanently afxed within 150 mm of the ller inlet. The design and construction of the petrol ller inlet shall prevent the insertion of a leaded petrol nozzle. Overseas sourced engines will be accepted provided that the engine is manufactured to a standard equivalent to ADR 37/01. Every vehicle shall be so constructed that crankcase gases are not permitted to escape into the atmosphere. A label of durable material which includes the engine tune up specications shall be permanently afxed in the engine compartment. The label may be a copy of the original donor engine label. In the case of vehicles operating on petrol, an Evaporative Emission Control System which will prevent vaporised fuel from the fuel system being emitted into the atmosphere, shall be tted. If the engine is modied away from its standard specications then the vehicle must be tested to ADR 37/01 or by an IM240 emission testing facility or by an alternative test acceptable to DTEI. ADR 42/.. GENERAL SAFETY REQUIREMENTS Intent To specify design and construction requirements to ensure safe operation of vehicles. Requirements Bonnet Latching Any movable body panel forward of the windscreen that serves to cover an engine, luggage, storage or battery compartment must be provided with a latch system. A panel opening from the front which in any open position partially or completely obstructs a drivers forward view through the windscreen shall be provided with a second latch position on the latch system or with a second latch system. Diesel Engines A locking device shall be provided which prevents the engine from being started by any accidental or inadvertent means. (The locking device must act on the engine and prevent it from starting, should it be cranked by accidental means). Steering System The centre line of the steering control must not be located to the left of the centre line of the vehicle. Any component of the steering system which is essential to the steering operation shall be designed to transmit energy by mechanical means only. Failure of any non-mechanical component of the steering system must not prevent effective steering of the vehicle. Standard Controls for Automatic Transmission All motor vehicles equipped with an automatic transmission shall be tted with a starter interlock that renders the engine starter inoperative when the transmission control lever is in any forward or reverse drive position. Electrical Wiring, Connections & Installations The wiring of electrical equipment other than the high tension ignition wiring shall: be supported at intervals of not more than 600 mm be insulated at joints be located in such a position that it cannot become overheated, cannot contact moving parts nor constitute a re hazard owing to its proximity to the fuel system be protected from chang. The edge of all holes in metal through which the wiring passes shall be rolled or bushed with a grommet of rubber or equivalent insulating material. Exhaust Outlets The exhaust outlet shall extend at least 40 mm beyond the further most outboard or rearmost joint of the oor pan which is not continuously welded or permanently sealed which could permit direct access of exhaust gases to the passenger compartment, but not beyond the perimeter of the vehicle when viewed in plan. The exhaust outlet, if to the side of the vehicle, shall discharge to the right hand side of the vehicle and downwards at an angle to the horizontal of not less than 15 degrees and not more than 45 degrees. The exhaust outlet, if to the rear of the vehicle shall discharge at not more than 10 degrees above or 45 degrees below the horizontal. External or Internal Protrusions No vehicle shall be equipped with: any object or tting, not technically essential to such vehicle which protrudes from any part of the vehicle so that it is likely to increase the risk of bodily injury to any person any object or tting technically essential to such vehicles unless its design, construction and conditions and the manner in which it is afxed to the vehicle are such as to reduce to a minimum the risk of bodily injury to any person 17 any object or tting which, because it is pointed or has a sharp edge, is likely to increase the risk of bodily injury to any person any bumper bar the end of which is not turned towards the body of the vehicle to a sufcient extent to avoid any risk of hooking or grazing. Field of View A motor vehicle must not be constructed in a manner which prevents the driver from having an adequate view of trafc on either side of the vehicle and in all directions in front of the vehicle to enable the vehicle to be driven with safety. No passenger seating position may be more than 100 mm in front of the drivers seating position when both seats are in the rear most position of adjustment. No motor vehicle must be constructed with a passenger seating position at the righthand side of the driver. Wheel Guards (Mudguards) The vehicle must be provided with wheel guards (part of the bodywork, mudguards etc) which shall be so designed as to protect other road users, as far as practicable, against thrown-up stones, mud, ice, snow and water and to reduce for those users the dangers due to contact with the moving wheels. The wheel guards shall meet the following requirements when the wheels are in the straight ahead position: a. In the part formed by radial planes at an angle of 30 degrees to the front and 50 degrees to the rear of the centre of the wheel (i.e. the part of the mudguard between D and E in Figure 12), the overall width (q) of the wheel guards must be at least sufcient to cover the tyre Section Width (b) of the tyres tted to the vehicle, taking into account the extremes of tyre/ wheel combinations that may be tted to the vehicle. b. The rear of the wheel guards must not terminate above a horizontal plane 150 mm above the centre of the wheel and the intersection of the edge of the wheel guards with this plane (point A, Figure 12) shall lie outside the centreline of the tyre. c. The contour and location of the wheel guards shall be such that they are as close to the tyre as possible and they shall satisfy the following requirements: The lower lip of the outer edge of the guard shall be at least 30 mm deep directly above the centre of the wheel. This depth (p) may be reduced progressively to zero at points D and E.
The wheel guards may consist of several components, provided that no gaps exist between or within the individual parts when assembled. The wheel guards shall be securely attached. However they may be detachable either as a unit or in parts. The front wheel guard itself or in conjunction with other components (e.g. bumper bars) of the vehicle body or chassis shall prevent direct contact with the upper half of the wheel in a forward collision. 18 Brake Tubing & Brake Hose Air or vacuum brake tubing and air and vacuum brake hose, exible and hydraulic power hose between the brake power unit and the master cylinder or its equivalent shall conform to SAE, or other approved standards specied for air/vacuum or hydraulic tubing or hose. Brake tubing and hoses are to be tted to the vehicle to prevent chang, kinking or other mechanical damage under normal operating conditions. Reverse Gear An ICV shall be capable of being operated by the driver from the normal seating position in both forward and reverse directions. Television & Visual Display Units All television receivers or visual display units shall be installed so that no part of the image on the screen is visible to the driver from the normal driving position unless: a. the television receiver or visual display unit cannot be operated while the vehicle is moving, or b. the television receiver or visual display unit is a drivers aid. Examples of drivers aid include, closed- circuit security cameras, navigational or intelligent highway and vehicle systems (GPS), rear view screens and vehicle monitoring devices. All television receivers or visual display units and their associated equipment shall be mounted in a position which: does not obscure the drivers vision does not impede driver or passenger movement in the vehicle is unlikely to increase the risk of occupant injury. Windows & Ventilation At least half the number of windows shall be capable of being opened or the vehicle shall be provided with an alternative method of ventilation. Power Operated Window Systems Power operated windows, if tted shall comply with the requirements of ADR 42/.. Clause 19.3 Power Operated Window Systems. Power operated windows should not be operational 45 seconds after the ignition is turned off. Warning Devices Audible No device capable of producing a sound resembling that produced by any siren, repeater horn, bell or whistle shall be attached to an ICV. A repeater horn is any device which emits an audible sound alternating between different tones or frequencies on a regular time cycle. Every motor vehicle shall be tted with at least one warning device capable of giving sufcient audible warning of the presence of the vehicle. It shall give an audible signal having constant amplitude and frequency characteristics. It may be powered by any energy source including compressed air. A further device may be tted which emits an intermittent audible signal only when reverse gear is selected. The audible signal is to warn persons of the proximity of the reversing vehicle and should not be louder than is necessary for this purpose. Demisting of Windscreens Every motor vehicle having a windscreen must be tted with a device capable of removing condensed moisture from the inside of the windscreen. Windscreen Wipers & Washers Every motor vehicle having a windscreen must be tted with a power-driven windscreen wiping system. Every motor vehicle having a windscreen wiping system must have a windscreen washing system that can direct water on to the windscreen within the area swept by the windscreen wipers. The device or devices for operating the wipers and washer must be able to be controlled by the driver in the normal driving position. ADR 43/.. VEHICLE CONFIGURATION & MARKING Intent To specify requirements for vehicle conguration and dimensions. Requirements Turning Circle Every motor vehicle shall have a turning circle in either direction (as determined by reference to the extreme outer edge of the tyre track at ground level) not exceeding 25 metres in diameter. Ground Clearance The ground clearance of a vehicle measured from a horizontal road surface to any point of the underside of the vehicle except the tyres, wheels and wheel hubs shall, with the vehicle in its maximum laden condition be not less than 100 mm. Note: For vehicles with a wheelbase dimension exceeding 3 m or with rear overhang exceeding 1.5m refer to ADR 43/.. Overall Width The overall width of a vehicle must not exceed 2,500 mm. 19 20 ADR 46/.. HEADLAMPS Intent To specify the photometric requirements for headlamps which will provide adequate illumination for the driver of the vehicle without producing undue glare for other road users. Requirements Only lamps complying with ADR 46/.. are acceptable. The headlamps shall be suitably handed for right-hand drive and the colour of light emitted shall be white. Headlamps shall be so designed and made, that in normal use despite the vibration to which they may then be subjected, their satisfactory operation continues to be ensured. The components by which the lament globe is xed to the reector shall be so made that, even in darkness, the globe can be xed in no position but the correct one. The headlamps shall be so made that they give adequate illumination without dazzle on the passing beam, and good illumination on the driving beam. ADR 13/.. species that the vehicle shall have: two or four main-beam headlamps positioned at the front of the vehicle and tted in such a way that the light emitted does not cause discomfort to the driver either directly or indirectly through the rear view mirrors or other reecting surfaces of the vehicle the outer edges of the illuminating surfaces of the main-beam headlamps must not be closer to the outer edge of the vehicle than the outer edges of the illuminating surface of the dipped- beam headlamps the main-beam headlamps may be switched on either simultaneously or in pairs. For changing over from the main-beam to the dipped-beam all main-beam headlamps shall be switched off simultaneously a circuit-closed main-beam headlamp tell-tale the colour of which shall be blue two dipped-beam headlamps positioned at the front of the vehicle with the outer edges of the illuminating surfaces being not more than 400 mm from the extreme outer edges of the vehicle and with the inner edges of the illuminating surfaces being not less than 600 mm apart the lower edge of the illuminating surfaces shall be not less than 500 mm above the ground and the higher edges not more than 1200 mm above the ground the dipped-beam may remain switched on at the same time as the main-beams the control for changing over to the dipped-beam shall be a hand or foot operated switch within reach of the driver in the normal driving position. The dipped beam and main-beam headlamps may be grouped together or with other front lamps. ADR 47/.. RETRO-REFLECTORS Intent To specify the dimensional, photometric and stability requirements for retro- reectors which will ensure that they effectively warn of the presence of the vehicle and continue to do so in normal use. Requirements Retro-reecting devices must be so constructed that they function satisfactorily and will continue to do so in normal use. The components of retro-reecting devices must not be capable of being easily dismantled and the retro-reecting optical units must not be replaceable. The outer surface of retro-reecting devices must be easy to clean and so it must not be a rough surface. Only complying reectors will be accepted. The shape of illuminating surfaces of retro-reecting devices must t within a 200 mm diameter circle. The shape of the illuminating surfaces must be simple and not easily confused at normal observation distances with a letter, number or a triangle. The colouring of retro-reecting optical units by means of paint and varnish is not permitted. ADR 13/.. species that: a vehicle shall have two or more rear retro-reectors (non-triangular) afxed at the rear of the vehicle with the outer edge of the illuminating surface being not more that 400 mm from the extreme outer edge of the vehicle the retro-reectors shall not be less than 250 mm nor more than 900 mm above the ground they shall be visible in the horizontal plain up to 30 degrees either side of centre and up to 15 degrees above and below the horizontal the illuminating surface of the retro- reectors may have parts in common with any other red lamp situated at the rear the rear retro-reectors shall be red. ADR 48/.. REAR REGISTRATION PLATE ILLUMINATING DEVICES Intent To specify the lighting requirements for rear registration plate illuminating devices which will ensure that the rear registration plate is adequately illuminated. Requirements The light of the lamp used in the illuminating device must be sufciently colour-less not to cause any appreciable change in the colour of the registration plate. ADR 13/.. species that: the vehicle shall have a rear registration plate lamp so positioned that it will illuminate the site of the registration plate the eld of visibility of the illuminated surface shall be 5 degrees above and below the horizontal and 30 degrees to either side. The South Australian Road Trafc (Vehicle Standards) Rules 1999 require that the number plate can be read at night at a distance of 20m from the rear of the vehicle. ADR 49/.. FRONT & REAR POSITION (SIDE) LAMPS, STOP LAMPS AND END-OUTLINE MARKER LAMPS Intent To specify the photometric requirements for vehicle light-signalling devices which will signal to other road users the position, orientation and movement of the vehicle without producing undue glare for other road users. Requirements Front Position Lamps ADR 13/.. species that: the vehicle shall have two front position (side) lamps which shall emit a white light they shall be so positioned at the front of the vehicle that the outer edges of the illuminating surfaces are not more than 400 mm from the extreme outer edges of the vehicle they shall be not less than 350 mm nor more than 1500 mm above the ground they shall be visible at all horizontal angles between 45 degrees inboard and 80 degrees outboard and at all vertical angles between 15 degrees above and below the horizontal. Rear Position Lamps ADR 13/.. species that: the vehicle shall have two rear position (side) lamps which emit a red light they shall be so positioned at the rear of the vehicle that the outer edges of the illuminating surfaces are not more than 400 mm from the extreme outer edges of the vehicle they shall be not less than 350 mm nor more than 1500 mm above the ground they shall be visible at all horizontal angles between 45 degrees inboard and 80 degrees outboard and at all vertical angles between 15 degrees above and below the horizontal. Stop Lamps ADR 13/.. species that: the vehicle shall have two stop lamps which emit a red light they shall be so positioned at the rear of the vehicle that the outer edges of the illuminating surfaces are not more than 400 mm from the extreme outer edges of the vehicle they shall be not less than 350 mm nor more than 1500 mm above the ground they shall be visible at all horizontal angles between 45 degrees inboard and outboard and at all vertical angles between 15 degrees above and below the horizontal the lamps must light up when the service brake is applied. They need not function if the engine control is in the off position i.e. ignition off. ADR 51/.. FILAMENT GLOBES Intent To specify the dimensional and photometric requirements for lament globes which will ensure interchangeability and correct functioning when installed in a lamp. Requirements All lament globes installed in vehicle lamps must comply with the requirements of ADR 51/.. Filament Lamps. (Most commercially available automotive light globes will comply with ADR 51/..) ADR 60/.. - CENTRE HIGH- MOUNTED STOP LAMP Intent To specify requirements for supplementary Centre High-Mounted Stop Lamp on the rear of the vehicle to provide an additional indication to other road users, that the driver of the vehicle is applying the service brakes. The colour of the light emitted shall be red. The lamp shall: have an effective projected luminous area of not less than 30 square centimetres not contain symbols, letters or characters other than those necessary for part number, manufacturers identication and/or approval number identication provide access for convenient replacement of the globe without the use of special tools provide a steady warning light not be grouped with any other lamp not be combined with any other lamp or reective device not be reciprocally incorporated with any other lamp be illuminated when the service brakes of the vehicle are applied. The lamp is to be mounted such that it is: in width - on the vehicles median longitudinal plane in height either not more than 150 mm above the bottom edge of the rear window or not less than 850 mm above the ground facing rearward if the lamp is mounted inside the vehicle it shall be shrouded to the glass, or other means shall be provided to minimise reections from the light of the lamp upon the rear window glazing that might be visible to the driver when viewed directly, or indirectly, in the rear vision mirror. 21 22 ADR 61/.. VEHICLE MARKING Intent To specify requirements for vehicle marking. Requirements Identication Number (VIN). Every vehicle shall have a unique Vehicle Identication Number (VIN). The VIN for an ICV is issued by DTEI, Vehicle Standards, and must be applied to the vehicle in accordance with the instructions contained in the Statement of Requirements for the vehicle. The Statement of Requirements is also issued by Vehicle Standards and must accompany the vehicle when it is presented for its Roadworthy Inspection. Engine Number An identication number shall be legible and permanently stamped on the main component of the engine at the time of its manufacture and shall be located where it can readily be seen when the engine is installed in the vehicle. Registration Plates Provision shall be made for mounting a registration plate that is to be afxed to the front and rear of the vehicle so that no part of the registration plate will be more than 1300 mm from the ground. No part of the vehicle, including any production options or equipment must be located to obscure any part of the registration plate(s). DYNAMIC OCCUPANT PROTECTION ADR 69/.. FULL FRONTAL IMPACT OCCUPANT PROTECTION, ADR 72/.. DYNAMIC SIDE IMPACT OCCUPANT PROTECTION ADR 73/.. OFFSET FRONTAL IMPACT OCCUPANT PROTECTION These ADRs involve crash testing of vehicles containing wired anthropomorphic dummies to verify compliance. Individually Constructed Vehicles are not required to verify compliance with these ADRs due to the costly, complex and destructive nature of the crash testing, however: a. Vehicle designers should consider crash survivability, and occupant protection as high priority and incorporate features that are likely to minimise injury to occupants in the event of an accident. b. A metal placard must be tted to the vehicle warning occupants that the vehicle has not been tested in accordance with Australian Design Rules 69, 72 and 73. See gure 13. c. A permanent label must be sewn on to the seatbelt webbing of the front outboard seating positions, just below the upper anchorage when the seatbelt is fully retracted, so that it is easily visible to the occupant before the seatbelt is secured. The label should contain the warning shown in gure 13 and should be at least 100 x 30 mm in size. d. The warning displayed on the metal placard and the seatbelts must also be contained in the vehicle handbook or otherwise be supplied with the vehicle. AIRBAGS Due to the highly technical and complex nature of airbag design and the associated calibration necessary to ensure proper operation without false deployment, it is not recommended to t airbags to ICVs. GAS DISCHARGE HEADLAMPS Gas discharge headlamps may be tted to an ICV but are inherently complex, expensive and are subject to additional requirements beyond that of regular headlamps. Refer to ADR 13/.. Installation of Lighting and Light Signalling Devices on other than L-Group Vehicles and ADR 77/.. Gas Discharge Headlamps. Further information Contact the Department for Transport, Energy and Infrastructure: Vehicle Services Kateena Street, Regency Park PO Box 1 Walkerville SA 5081 Telephone: 1300 882 248 Internet: www.dtei.sa.gov.au Fax: (08) 8348 9533 This Information Manual is provided for information only. No responsibility will be accepted from the use of the information contained in this Information Manual. MR850 03/07 WARNING This vehicle has not been tested in accordance with the following Australian Design Rules ADR69/.. Full Frontal Impact Occupant Protection ADR72/.. Dynamic Side Impact Occupant Protection ADR73/.. Offset Frontal Impact Occupant Protection It may not provide the level of occupant protection required by these rules Figure 13 23 Notes MR850 03/07